Non-combustible smoking article and method of use thereof

ABSTRACT

A non-combustible smoking article and method of use thereof may be provided. The non-combustible smoking article may include a composite filter forming an elongated, cylindrical rod. The composite filter may further include a cavity having a nicotine source; an aerosol-forming substrate proximate the nicotine source; and at least one capsule filled with an additive for modifying a characteristic of inhalable vapor. An internal heater may be inserted into at least the nicotine-containing cavity of the composite filter. A peripheral heating source may also be disposed along an exterior length of the composite filter. The internal heater and the peripheral heating source may be activated to heat at least a portion of the composite filter, wherein the heat generates inhalable vapor to be drawn and inhaled by a consumer.

BACKGROUND

Heat-not-burn (HNB) products have been proposed as a non-combustiblealternative to traditional cigarettes. Such products generate inhalablevapor by heating, rather than burning, tobacco and/or other tobaccoconstituents. The resulting aerosol, inhaled by the consumer, typicallycontains nicotine and other additives used to enhance user experience.Essentially, successful HNB products must release an abundance of fluid(i.e., gaseous) to provide a dose of at least nicotine and the fullmouth sensation of smoking. These molecular attributes are carried inthe fluid, rather than in the tobacco particulates of combustiblecigarettes.

In order to gain mass-market appeal as a smoking replacement, HNBproducts try to replicate, and/or best approximate, the sensation ofsmoking conventional cigarettes. It would, therefore, be desirable toprovide a non-combustible smoking article that allows consumers tocustomize their smoking experience in much of the same way asconventional cigarette options allow.

Various methods for modifying the sensory attributes of conventionalcigarettes are known in the art. For example, specialized cigarettefilters are known to incorporate a variety of elements, such asflavor-releasing capsules, in order to modify the characteristics of themainstream smoke that passes through those filter elements. Theseelements may be used for a variety of purposes, such as imparting flavoror reducing some chemical elements from the cigarette smoke to beinhaled by the consumer. Accordingly, it would be desirable to provide anon-combustible smoking article that allows different sensoryexperiences at the discretion of the consumer.

SUMMARY

According to an exemplary embodiment, a non-combustible smoking articlemay be described herein. The non-combustible smoking article may includea composite filter forming an elongated, cylindrical rod. The compositefilter may further include a cavity having a nicotine source; anaerosol-forming substrate proximate the nicotine source; and at leastone capsule filled with an additive for modifying a characteristic ofinhalable vapor. An internal heater may be inserted into at least thecavity having the nicotine source of the composite filter. A peripheralheating source may also be disposed along an external length of thecomposite filter.

According to another exemplary embodiment, a method of using anon-combustible smoking article may be provided herein. The method mayinclude providing a non-combustible smoking article having a compositefilter, the composite filter further comprising: a cavity having anicotine source; an aerosol-forming substrate proximate the nicotinesource; and at least one capsule filled with an additive for modifying acharacteristic of inhalable vapor. The method may further include thesteps of: inserting an internal heater into at least the cavity havingthe nicotine source of the composite filter; applying a peripheralheating source to a length of the composite filter; and activating theinternal heater and the peripheral heating source to heat at least aportion of the composite filter, wherein the heat generates theinhalable vapor to be drawn and inhaled by a consumer.

BRIEF DESCRIPTION OF THE FIGURES

Advantages of embodiments of the present invention will be apparent fromthe following detailed description of the exemplary embodiments. Thefollowing detailed description should be considered in conjunction withthe accompanying figures in which:

FIG. 1 is a cross-sectional view illustrating an exemplary embodiment ofa composite filter in accordance with the present invention;

FIG. 2 is a cross-sectional view illustrating another exemplaryembodiment of a composite filter;

FIG. 3 is a perspective view illustrating an exemplary embodiment of aheat-initiating capsule used in conjunction with a composite filter; and

FIG. 4 is a perspective view illustrating an exemplary embodiment of anon-combustible smoking article.

DETAILED DESCRIPTION OF THE FIGURES

Aspects of the present invention are disclosed in the followingdescription and related figures directed to specific embodiments of theinvention. Those skilled in the art will recognize that alternateembodiments may be devised without departing from the spirit or thescope of the claims. Additionally, well-known elements of exemplaryembodiments of the invention will not be described in detail or will beomitted so as not to obscure the relevant details of the invention.Further, to facilitate an understanding of the description discussion ofseveral terms used herein follows.

As used herein, the word “exemplary” means “serving as an example,instance or illustration.” The embodiments described herein are notlimiting, but rather are exemplary only. It should be understood thatthe described embodiments are not necessarily to be construed aspreferred or advantageous over other embodiments. Moreover, the terms“embodiments of the invention,” “embodiments,” or “invention” do notrequire that all embodiments of the invention include the discussedfeature, advantage, or mode of operation.

According to an exemplary embodiment, a non-combustible smoking articlemay be described herein. The non-combustible smoking article may includea composite filter. The composite filter may further include a cavityhaving a nicotine source; an aerosol-forming substrate proximate thenicotine source; and at least one capsule filled with an additive formodifying a characteristic of inhalable vapor. An internal heater may beinserted into the non-combustible smoking article, piercing andextending through at least the nicotine-containing cavity of thecomposite filter. A peripheral heating source may also be applied to anexterior of the smoking article, along a length of the composite filter.Both heating components (i.e., internal heater and peripheral heatingsource) may be activated to warm the composite filter, ensuring a moreuniform heat distribution profile across the smoking article. Theheating, not burning, of the product generates an inhalable vapor, whichis drawn through the smoking article and condensed into an aerosol to beinhaled by the consumer. The composite filter may differ in size, shape,and/or construction to impart a customizable smoking experience.

Referring now to the figures, FIG. 1 may illustrate a longitudinalcross-section of an exemplary embodiment of a composite filter 100according to the present invention. The composite filter 100 may bespecifically designed to function with the heating components of thenon-combustible smoking article. In some exemplary embodiments, thecomposite filter 100 may provide a pressure drop to control airflowthrough the non-combustible smoking article.

The composite filter 100 may generally form an elongate, cylindrical rod102, which can be partitioned into a number of different segments. Eachsegment may have a specific purpose, and/or one or more substancesdisposed therein. In some exemplary embodiments, for example, thecomposite filter 100 may include a filter stopper 104, a cavity 106having a nicotine source 108, an aerosol-forming substrate 110 proximatethe nicotine source 108, and at least one capsule 112 filled with anadditive for modifying a characteristic of inhalable vapor.

The composite filter 100 may be constructed from a base filter material,such as cellulose, cellulose acetate tow, paper, cotton, polypropyleneweb, polypropylene tow, polyester web, polyester tow, or any combinationthereof. The base filter material may be enclosed in a wrapper 114. Thewrapper 114 may circumscribe the entire length of the filter 100. Thewrapper 114 may be formed from a paper stock tube. The paper stock tubemay be made, for instance, from flax, linen fiber, or any other suitablematerial known in the art. The paper stock tube may allow zero pressuredifferential and removals, whilst producing a longer (and more balancedlooking) product. In some exemplary embodiments, the paper tube may alsoallow the composite filter to be combined with a thinner, more porousplug wrap.

The tight retention and integrity of all segments into the product maybe ensured by multiple anchor lines applied to the inside of thewrapper. The anchorage adhesive may be, for example, a hot melt adhesiveor an emulsion-based (e.g., EVA, PVA or PVOH) adhesive. The number oflines and the ration of adhesive may depend on the application and canvary according to the needs and design.

In some exemplary embodiments, a non-combustible segment may be providedat either end of the composite filter 100. The non-combustible segmentmay be constructed from cellulose acetate or other non-burning materialknown in the art. In some exemplary embodiments, for example, thenon-combustible segment may be made from polylactic acid (PLA) materialor ceramic segments. The non-combustible segment may form a filterstopper 104 that is attached to an end portion of the composite filter100. The filter stopper 104 may be approximately 2 mm in diameter,thereby allowing easier penetration of an internal heating probe, and/orconsecutive cleaning of said probe once removed from the filter body.

As shown in FIG. 1, the composite filter 100 may further include anicotine-carrying cavity 106 extending along a length of the filter 100,and defined by an interior portion thereof. The nicotine-carrying cavity106 may be positioned at, or adjacent to, the filter stopper 104. Atobacco material 108 may at least partially fill a volume of thenicotine-carrying cavity 106. The cavity 106 may also be filled withother nicotine-carrying material(s), such as Sepiolite, Perlite, superabsorbent polymers, and/or any other known nicotine-carrying substanceas would be understood by one of ordinary skill in the art.

In some exemplary embodiments, the tobacco material 108 may be formed bygrinding or otherwise comminuting parts of the tobacco plant (e.g., leaflamina, stem, etc.). In some exemplary embodiments, the tobacco material108 may be composed of one or more of the following: tobacco dust,tobacco powder, tobacco fines, reconstituted tobacco sheet, cast leaf,and other tobacco particulates formed during, for example, the tobaccoprocessing operation.

The tobacco material 108 may be treated with an aerosol-formingsubstrate 110, for example glycerin and/or propylene glycol. Theaerosol-forming substrate 110 may be introduced into the cavity 106 by aspraying means, such as a spray nozzle, atomization apparatus, injectionnozzle, gravity-actuated nozzle, pressure and/or gravity-actuatedapplying apparatus, or any other suitable device as would be understoodby one of ordinary skill in the art. The aerosol-forming substrate 110may be applied via the spraying means before, and/or during, and/orafter the insertion of the tobacco material 108 into the cavity 106.

In some exemplary embodiments, and as shown in FIGS. 1-2, theaerosol-forming substrate 110 may be introduced into the filter 100 asan encapsulated agent. The encapsulation can control the timing of therelease of the aerosol-forming substrate 110, thereby allowing greatercontrol of the puff yield. In some exemplary embodiments, theencapsulation may also increase the stability of the agent and/orprevent its migration within the composite filter 100. Theaerosol-forming capsule may be disposed within a segment of thecomposite filter adjacent to the nicotine-carrying cavity 106.

The aerosol-forming capsule may include a shell having anaerosol-forming substance 110 therein. The shell may be formed from avariety of materials, so as to conform to desired physical propertiesfor shell. In some exemplary embodiments, for example, the shell may beformed from a water-soluble material, and may thus dissolve upon contactwith water or exposure to a desired amount of humidity. In otherexemplary embodiments, the shell may be made from a gelatinous material.In some exemplary embodiments, the shell may be frangible uponapplication of sufficient pressure. Thus, if pressure is applied to acapsule, for example by squeezing, the capsule may rupture, therebyreleasing the substance therein. The pressure required to rupture shellmay be varied to meet desired specifications.

In some exemplary embodiments, the aerosol-forming capsule may bedisposed substantially coaxial to the longitudinal axis of the compositefilter 100. The aerosol-forming capsule may be inserted into thecomposite filter 100 by on-line or in-line addition. Any known insertiontechnique may be employed, such as those described in U.S. Pat. No.8,622,882, and U.S. Pat. No. 8,303,474, which are incorporated herein byreference in their entirety. In some exemplary embodiments, theaerosol-forming substrate (e.g., glycerin and/or propylene glycol)and/or nicotine may be introduced into the cavity 106 by any of thespraying means described herein.

FIG. 2 may illustrate a longitudinal cross-section of another exemplaryembodiment of a composite filter. In FIG. 2, the same reference numbersas those in FIG. 1 represent the same or corresponding elements. Asshown in FIG. 2, the capsule carrying aerosol-forming substrate 110 maybe disposed directly within the nicotine-carrying cavity 106, andsurrounded by the tobacco material 108.

The nicotine-carrying cavity 106 may be formed using wrapping materialas further described below. An endless plug wrap paper with differenttype segments in length may be formed, thus creating a cavitytherebetween. When the plug wrap paper is overlapped, a cavity may formbetween segments. The cavity dimensions may be as follows: the diametermay vary between 4.5-12 mm, the height may vary between 4-67 mm. Thismay be accomplished using forced feeding, plunger, pusher, suction,and/or blowing technologies. Both gravity and forced feeding into thecavity may be available, and can be using according to the need ofapplication. For example, the technology may include gravity-actuatedcavity filling stations with predetermined amounts of material. In oneexemplary embodiment, for example, the volume of the nicotine-carryingcavity 106 may range from approximately 63 to 7578 mm³. The filling rateof the cavity 106 can vary depending on consumer preference. Forexample, the filling rate (i.e., tobacco volume to cavity volume ratio)of the cavity 106 may range from approximately 5% to 95% full.

FIG. 1 may further illustrate the composite filter 100 having at leastone capsule 112 disposed within an additional segment of the compositefilter 100. Each capsule 112 may include a shell 116 filled with anadditive for modifying a characteristic of the aerosol to be inhaled bya consumer. In some exemplary embodiments, for example, the capsule 112may release flavorings or aromatic material into the air stream passingthrough the filter 100. In some exemplary embodiments, these capsules112 may also alter other chemical or physical characteristics of theinhalable vapor, such as, for example, providing a cooling or moisteningeffect. The quantity, size, and/or composition of the capsules 112 mayvary depending on a desired smoking experience.

The shell 116 may be formed from a variety of materials, so as toconform to desired physical properties for shell 116. In some exemplaryembodiments, for example, the shell 116 may be formed from awater-soluble material, and may thus dissolve upon contact with water orexposure to a desired amount of humidity. In other exemplaryembodiments, the shell 116 may be made from a gelatinous material. Insome exemplary embodiments, the shell 116 may be frangible uponapplication of sufficient pressure. Thus, if pressure is applied to acapsule 112, for example by squeezing, the capsule 112 may rupture,thereby releasing the additive therein. The pressure required to ruptureshell 116 may be varied to meet desired specifications. For example,each shell 116 may be adapted to rupture upon application of pressure bya consumer's fingers. In some exemplary embodiments, the shell 116 mayrupture when a force of between approximately 19 newton (N) andapproximately 11 N is applied thereto. Alternatively, the shell 116 maybe air permeable so that it does not need to be ruptured in order toefficiently utilize the additive therein. For example, the shell 116 maybe microporous.

As shown in FIGS. 1 and 2, the shell 116 may be spherical, but any othershape may be utilized as desired. In some exemplary embodiments, theshell 116 is coaxial with the composite filter 100 as a whole. Thediameter of each capsule 112 may vary between 1-6 mm. At least onecapsule 112 may include, but is not limited to, liquid having one ormore of the following flavors: mint, peppermint, vanilla, apple, lemon,coffee, chocolate, and ginger. In some exemplary embodiments, one ormore capsules 112 may include a non-flavor additive intended to cooldown the inhaled aerosol.

FIG. 3 may illustrate a perspective view of an exemplary embodiment of aheat-initiating capsule 300. The heat-initiating capsule 300 may providean alternative way of introducing heat to the composite filter byfacilitating an exothermic reaction of chemical reactants encapsulatedtherein. The heat-initiating capsule 300 may be provided in additionalto, or as a substitute for, one or more independent heating components(e.g., probe heater, peripheral heating source). The capsule 300 may bedisposed within the composite filter itself, at a non-combustiblesegment or filter stopper. The action required to initiate the heatreaction of the capsule 300 may depend on the specific design thereof,but may generally include the release, and preferably the mixing, of allencapsulates contained therein.

The heat-initiating capsule 300 may form a multi-compartment (e.g.,capsule-in-capsule) structure having at least two segregated chemicalreactants. As illustrated in FIG. 3, for example, the heat-initiatingcapsule 300 may include a first inner capsule 302 and a second innercapsule 304 surrounded by an outer capsule shell 306. The first innercapsule 302 may include a first shell 308 and a first chemical reactant310 disposed within the first shell 308. Similarly, the second innercapsule 304 may include a second shell 312 and a second chemicalreactant 314 disposed within the second shell 312. It should becontemplated, however, that any other suitable configuration and/orphysical barrier(s) may be employed to isolate the at least two chemicalreactants 310, 314 within the capsule 300, as would be understood by oneof ordinary skill in the art.

Each capsule shell 306, 308, 312 may be formed from a variety ofmaterials, so as to conform to desired physical properties for thatrespective capsule. In some exemplary embodiments, for example, one ormore shells may be formed from a water-soluble material, and may thusdissolve upon contact with water or exposure to a desired amount ofhumidity. In other exemplary embodiments, one or more shells may be madefrom a gelatinous material. In some exemplary embodiments, one or moreshells may be frangible upon application of sufficient pressure. Thus,if pressure is applied to capsule 300, for example by squeezing via aconsumer's fingers, one or more shells 306, 308, 312 may rupture,thereby releasing the chemicals reactants 310, 314 from therewithin.

Each capsule 300, 302, 304 may be present in various shapes, sizes,and/or configurations. The shape of any one capsule may, for example, besubstantially ellipsoidal, spherical, cylindrical, rectangular,irregular, or as otherwise needed for an intended application. It shouldbe appreciated that size limitations may exist based on the availablespace within the composite filter. Additionally, the chemicals reactants310, 314 may be present in any form (i.e., gaseous, liquid, solid, orany combination thereof) and composed of any desired element, compound,or mixture capable of triggering an exothermic response upon initiatingcontact and/or suitable activation. In one exemplary embodiment, forexample, the chemical reactants 310, 314 may include a metal and astrong oxidizing agent. It should be contemplated, however, that avariety of reactants may be substituted to produce an exothermicreaction with desired specifications (e.g., rate of reaction,temperature, etc.) as would be understood by one of ordinary skill inthe art.

FIG. 4 may illustrate a perspective view of an exemplary embodiment of anon-combustible smoking article 400. The non-combustible smoking article400 may include a composite filter 402 having differentiated segments.In some exemplary embodiments, the composite filter 402 may include acavity 404 having a nicotine source 406, an aerosol-forming substrate408 proximate the nicotine source 406, and at least one capsule 410filled with an additive for modifying a characteristic of aerosol to beinhaled by a consumer.

One or more heating sources may also interact with the filter 402. Forexample, an internal heater 412 may be inserted into at least the cavity404 having the nicotine source 406 of the composite filter 400. In someexemplary embodiments, the internal heater 412 may also rupture acapsule filled with an aerosol-forming substrate 408. The internalheater 412 may take any suitable form, including a heating blade,heating plate, electrically-powered linear heating element, and thelike. The cross-sectional shape of the internal heater 412 may takevarious forms, including but not limited to: cylindrical, triangular,rectangular, conical, elliptical, and pyramidal.

A peripheral heating source 414 may also be disposed along an externallength of the composite filter 400. The peripheral heating source 414may take any suitable form known in the art. Both heating components412, 414 can be activated to warm the composite filter 402, ensuring amore uniform heat distribution profile across the smoking article.

The heating, not burning, of the product generates an inhalable vapor,which is drawn through the smoking article and condensed into an aerosolto be inhaled by the consumer. The heat applied to the composite filter402 can have different profiles along the length thereof, and/ordifferent temperatures at different time(s) depending on a predeterminedvariable, such as the number of puffs by a consumer. The peripheralheating source 414, for example, may include a plurality of heatingregions that operate independently from one another so that differentregions can activate at different times. In some exemplary embodiments,heat may not be applied at the filter stopper, or at any othernon-combustible segment. These heating characteristics may allow forsimultaneous and/or differentiated release of nicotine and/or theaerosol-forming substrate and/or the vapor additive.

Each heater 412, 414 may be provided as part of the non-combustiblesmoking article 400. The temperature of the internal heater 412 and/orthe peripheral heating source 414 may differentiate between 90° F. and350° F., and vary over time. The internal heater 412 and peripheralheating source 414 may be made of various materials, such as differenttypes of steel, ceramic, graphite, carbon, nichrome, Kanthal®,cupronickel, platinum, and gold. The heating temperatures may bepreprogrammed or controllable by the consumer.

The foregoing description and accompanying figures illustrate theprinciples, preferred embodiments, and modes of operation of theinvention. However, the invention should not be construed as beinglimited to the particular embodiments discussed above. Additionalvariations of the embodiments discussed above will be appreciated bythose skilled in the art.

Therefore, the above-described embodiments should be regarded asillustrative rather than restrictive. Accordingly, it should beappreciated that variations to those embodiments may be made by thoseskilled in the art without departing from the scope of the invention asdefined by the following claims.

What is claimed is:
 1. A non-combustible smoking article comprising: acomposite filter forming an elongated, cylindrical rod; the compositefilter further comprising: a cavity having a nicotine source; anaerosol-forming substrate proximate the nicotine source; and at leastone capsule filled with an additive for modifying a characteristic of atleast one of: the nicotine source and aerosol-forming substrate; aninternal heater inserted into at least the cavity having the nicotinesource; and a peripheral heating source disposed along an exteriorlength of the composite filter.
 2. The non-combustible smoking articleof claim 1, wherein the composite filter is constructed from a basefilter material.
 3. The non-combustible smoking article of claim 2,wherein the base filter material is at least one of: cellulose,cellulose acetate tow, paper, cotton, polypropylene web, polypropylenetow, polyester web, polyester tow, and any combination thereof.
 4. Thenon-combustible smoking article of claim 1, further comprising a wrapperthat circumscribes a length of the composite filter.
 5. Thenon-combustible smoking article of claim 4, wherein the wrapper isconstructed from a paper stock tube.
 6. The non-combustible smokingarticle of claim 5, wherein the paper stock tube is made from at leastone of: flax and linen fiber.
 7. The non-combustible smoking article ofclaim 1, wherein the nicotine source is a tobacco material.
 8. Thenon-combustible smoking article of claim 7, wherein the tobacco materialis at least one of: tobacco dust, tobacco powder, tobacco fines,reconstituted tobacco sheet, cast leaf, and tobacco particulates.
 9. Thenon-combustible smoking article of claim 1, further comprising a filterstopper provided on a first end and on a second end of the compositefilter.
 10. The non-combustible smoking article of claim 9, wherein thefilter stopper is made from cellulose acetate.
 11. The non-combustiblesmoking article of claim 9, wherein a diameter of the filter stopper isapproximately 2 mm.
 12. The non-combustible smoking article of claim 1,wherein the cavity further comprises at least one nicotine-carryingmaterial.
 13. The non-combustible smoking article of claim 12, whereinthe nicotine-carrying material is at least one of: Sepiolite, Perlite,and super absorbent polymer.
 14. The non-combustible smoking article ofclaim 1, wherein the aerosol-forming substrate is at least one of:glycerin and propylene glycol.
 15. The non-combustible smoking articleof claim 1, wherein the aerosol-forming substrate is provided in atleast one capsule.
 16. The non-combustible smoking article of claim 9,further comprising a heat-initiating capsule disposed within the filterstopper provided on the first end of the composite filter.
 17. A methodof using a non-combustible smoking article comprising: providing anon-combustible smoking article having a composite filter, the compositefilter further comprising: a cavity having a nicotine source; anaerosol-forming substrate proximate the nicotine source; and at leastone capsule filled with an additive for modifying a characteristic ofinhalable vapor generated by the non-combustible smoking article;inserting an internal heater into at least the cavity having thenicotine source of the composite filter; applying a peripheral heatingsource to a length of the composite filter; and activating the internalheater and the peripheral heating source to heat at least a portion ofthe composite filter, wherein the heat generates inhalable vapor to bedrawn and inhaled by a consumer.
 18. The method of claim 17, wherein theaerosol-forming substrate is introduced into the cavity having thenicotine source via spraying means.
 19. The method of claim 17, whereinat least one of the internal heater and the peripheral heating sourceheat apply differentiated temperatures along the length of the compositefilter.
 20. The method of claim 17, wherein a temperature of the heatapplied by the internal heater and the peripheral heating source dependson a number of puffs taken by the consumer.